Operation Manual XA150_Version02.Compressed

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www.sperre.com Operation Manual XA150 Version 02 3

Congratulations on your X-range compressor!

Innovations:

Patented X-drive Patented cooling Registered design

The extraordinary X-range compressor is a new generation of true 1800 rpm compressors, and covers all capacities for the marinemarket. The Sperre X-range compressor is based on more than 70 years of experience.

This excellent compressor gives you several benefits:

Safety first – a fully enclosed structure

Green and clean – no oil mist to the environment

A new level of control

Easy to learn – one common platform

Less installation time – no special alignment

Easy plug-in for sensors

25% fewer wear parts – 50% more reliable

Best cooling efficiency in the market

Low vibration level – high grade of isolation

Improved standard scope of supply

Sperre has developed a unique chain of value, that‟s what it takes to produce reliable compressors that function smoothly for thelife of the ship.

Sperre congratulates you on your choice of compressor!




Contents

1 Introduction ............................................................................................ 5

1.1 Purpose ........................................................................................................................ 5

1.2

Annotations .................................................................................................................. 5

1.3 Abbreviations ................................................................................................................ 5

1.4 Tags on the compressor ............................................................................................... 6

1.5 Warranty ....................................................................................................................... 6

2 Personal safety ....................................................................................... 7

3 System description ................................................................................ 8

3.1 X-range compressor ..................................................................................................... 8

3.2 X-control ..................................................................................................................... 10

4 Technical data ...................................................................................... 11

5 User Interface ....................................................................................... 12

5.1 Keypad ....................................................................................................................... 12

5.2 LED indicators ............................................................................................................ 13

5.3 Display ....................................................................................................................... 14

5.4 Symbols ..................................................................................................................... 16

5.5 Menu structure ............................................................................................................ 18

6 Installation and Operation ................................................................... 22

6.1 Installation .................................................................................................................. 22

6.2 Before and after operation .......................................................................................... 23

6.3

General operation ....................................................................................................... 24 6.4 Internal system control (ISC) ....................................................................................... 28

6.5 Emergency operation .................................................................................................. 31

7 Troubleshooting ................................................................................... 32

7.1 Abbreviations .............................................................................................................. 32

7.2 Service warning (SW) and alarm (SA) ......................................................................... 32

7.3 Alarms (A) .................................................................................................................. 34

7.4 Start inhibits (S) .......................................................................................................... 36

7.5 Immediate stop shutdown errors (E) ............................................................................ 37

7.6 Errors when no alerts are displayed ............................................................................ 40




1 Introduction

1.1 Purpose

Sperre has produced this manual to provide information for all users of the compressorequipment. This includes information about the compressor‟s construction andoperation, as well as basic information regarding inspection and maintenance.

It is important that operators familiarize themselves with the contents of this instructionmanual, to ensure that use and maintenance work are carried out in the correct andsafe manner from the outset.

The maintenance intervals and individual technical data are average values based onexperience, and may vary depending on the compressor‟s operational parameters.

The supplier accepts no responsibility for damage resulting from careless operation orinadequate maintenance. Keep the compressor in good mechanical condition, andremember that preventive maintenance of the equipment reduces the danger of damageand unnecessary operational interruptions.

Sperre reserves the right to modify details without prior warning.

Note

Please note that all pictures anddrawings in this manual are forillustration only.

1.2 Annotations All safety directions must be respected in order to avoid damage to personnel, the environment and equipment. In this manual theannotations are used, as illustrated below:

WarningIndicates possibilities for hazards or unsafe practices, which COULD result in fatal orsevere personnel injuries or substantial product or property damage, if the requiredprecautions are not taken.

NoteDraws attention to specific information of technical significance that might not beobvious, or highlights important remarks in the procedures to follow.

1.3 Abbreviations

Abbreviation Description

BargCFD

CR

CW

dBA

DOL

HP

LP

IMO

ISC

MR

PMS

RPM

XA

XW

Unit of pressure (Barg = Bar gauge)Computerized Fluid Dynamics

Class Recommendation

Cooling Water

Decibel

Direct On Load

High Pressure

Low Pressure

International Maritime Organization

Internal System Control

Makers Recommendation

Planned Maintenance System

Revolutions Per Minute

X-range compressor Air-cooled

X-range compressor Water-cooled




1.4 Tags on the compressor

Danger

The compressor is remotely controlled

May start without warning

Danger

Hazardous voltage

Risk of electric shock

Caution

Burn hazard

Risk of hot surface

Before using or servicing the compressor

Read and understand the user manual

The cover must always be on whenrunning

Without the cover the compressor will bedamaged after running even for a shortperiod

To connect the signal cable, carefullyturn the plug to find the right insert point,then push carefully until a click appear

To disconnect, pull the ring on the plug

The oil has been drained from thecompressor

Do not start the compressor before the

correct oil quantity has been added

Compressor oil type.

For oil reference, visit www.sperre.com

Level sight glass

Correct oil level should be in centre oflevel sight glass

Drain oil Delivery air outlet Unloading and drain high pressure

The lifting eye bolt is certified for liftingthe single compressor with el-motor only

Rotation direction is counter clock wise,seen from compressor front.

Compressor rating plate

1.5 Warranty

The X-range compressor has a limited warranty that is valid only with use of original spare parts purchased through our Sperreoffice in Norway, Singapore, the Netherlands or China.

Please note that the warranty will be void if the equipment is misused or not handled in accordance with prescribed operating andservice standards.




2 Personal safetyPlease make yourself familiar with the content in this user manual before operating the compressor.

It is the responsibility of the user to ensure that appropriate controls and precautions are identified and applied in relation to thework envisaged by this document in accordance with relevant statutory, legal and industry requirements to protect the health andsafety of the persons undertaking the work.

All operation and service of the compressor is to be carried out by personnel who are familiar with the contents of this manual.

The compressor is a high pressure machine that must only be used to compress air. Unauthorized remodelling or modification ofthe compressor may result in a safety hazard, and is not permitted.

The compressor must never be operated without cover: the high temperature machine with rotating parts pose a great risk for thecrew.

Before any form of work is commenced on the compressor, the electrical power must be turned off at the starter panel and at themain switchboard, and the switch on the main switchboard must be marked with a notice indicating that repair work is in progress.The manual valve between the compressor and the air receiver must be closed, and the pressure must be released in allpressurized parts of the compressor.

The safety valves for LP air, HP air, cooling water and any other safety equipments must be inspected regularly. Damagedcomponents should be replaced with new, original parts. Please note that all safety valves are security sealed and any adjustment

of these valves is not recommended. The compressor must never be used if the safety equipment is defective.




3 System description

3.1 X-range compressor

The X-range compressor is a two stage, two cylinder compressor.

The radial fan [a] feeds fresh new ambient air to the inlet air filter [b] and further to the LP valve [c]. After first stage ofcompression the air is carried through the LP cooler [d] and further to the HP side of the compressor [e]. After laststage of compression the air is carried through the HP cooler [f] further through the cyclone separator [g] before thepressurized air is delivered to the air receiver.

X-cover

The robust steel cover protects the operator from hot surfaces and moving parts, thecover also protects the components and minimizes potential damage during transportand installation.

The radial fan and the distinctive shape of the cover are specially designed to worktogether. The radial fan builds up cooling air pressure, and the cover directs the flow ofcooling air in the optimal direction, ensuring that every component gets optimizedcooling air.

NOTE:The compressor must never be operated without cover: the high temperature machinewith rotating parts pose a great risk for the crew and the compressor will overheatwithout cover.




Cyclone separator

The high pressure cyclone ensures virtually water-free air, for XA and XW. The effectivecyclone separator removes at least 80% of remaining water droplets at 30 barg. It isequipped with an integrated non-return valve on the HP side.

The compressor has one automatic solenoid valve on HP side, for combined drainingand unloading functions.

Splash lubrication system

The splash lubrication system is a closed system. Extensive testing and simulationprove that this is an efficient and cost-effective solution.

The closed air breathing system ensures no oil mist to the environment:

Takes up oil mist from crankcase [a].

Condensed in the oil separator [b].

Most of the oil mist is condensed and led back into the oil sump [c].

The remaining oil mist is led into the intake air [d].

X-drive

The X-drive solution results in substantial benefits.

The flywheel function is integrated in rotating components. Flexible but torsion-proof

coupling, combined with the directly flanged electric motor, eliminates the need foralignment between the electric motor and the compressor.

Torsion-proof coupling makes it possible for the moving parts in the electric motor tofunction as the flywheel. The new coupling principle without wear parts ensures greateroperational reliability.

The configuration with the counterweight provides optimal balancing.

The result is a solution which is compact, easy to assemble and easy to maintain.




3.2 X-control

The X-control provides a complete package of easy-to-use control and monitoring functions in one standard, configurable module.

The controller is installed with a full graphic display with multiple languages. The display shows:

Start counter and running hours,

Instant readout of status information,

Logging of alarms and service history.

And more ...

The X-control simplifies preventive maintenance with an easy to read service countdown so there is no need to remove the cover of thecompressor to find out if maintenance necessary. If any blackout on board occurs, the compressor restart is automatically delayed toavoid power failure.

Items that an operator may need to view during routine operation, for example; pressure or temperature can easily be read from thedisplay. If a fault condition is active, the display will show a fault code and identification.




4 Technical dataFor further information and drawings regarding technical data, please refer to www.sperre.com.

Compressor XA150 – 30 barg

Charging capacity at 1775 / 1475 RPMPower requirements 1775 / 1475 RPM

Heat dissipation 1775 / 1475 RPM

Weight complete (standard motor)

Dimensions

Oil volume

Oil type

165 / 135 m

3

/h31 / 26 kW

29 / 24 kW

555 kg

1450 x 950 x 850 mm (L x W x H)

11 litres

Fully synthetic, ISO 100, piston comp.

Design

No. of cylinders / Cylinder arrangement

No. of compression stages

Cooling

Valve LP / Valve HP

2 / 90°V

2

Air cooled

1 Plate valve / 1 Reed valve

Operation parametersMax. delivery pressure

Start – stop pressure

Max. ambient temp. compressor

Max. ambient temp. controller

Max. ambient temp. electric motor

Air outlet temperature

Max. noise level

Max. vibration level / Min. isolation gradeSafety valve LP / HP

Rotation

Start Inhibits

40 barg

25 - 30 barg

55°C

55°C

45°C (55°C on request)

Approx 25°C above ambient

95 dBA (1800 rpm)

20mm/s-RMS / 90 %8 barg / 33 barg

Counter clockwise (compressor front)

Temp > 85°C / LP > x barg / HP> x barg

Alarm at 31 barg, shutdown at 32 barg

(fan needed above 50°C)

Below the IMO norm of 110 dBA

Gen. rec. 30 mm/s -RMS / 70%

Mechanical components

Non return valve air outlet

Oil & water separator HP

Safety valve LP / HP

Oil level sight glass

Air suction filter

Inter- and after-coolerThree vibration isolators

One lifting lug

Flexible tube air outlet

Flexible tube drain /unload

Integrated

Integrated

Integrated

Integrated

Integrated

IntegratedIntegrated

Integrated

Loose

Loose

Electrical components

Starter with controller

Transmitter LP

Transmitter HP

Trans. temp. outlet

Transmitter oil level

Valve drain - unload HP

Loose

Integrated

Integrated

Integrated

Integrated

Integrated



Alarm at 85°C, shutdown at 90°C

Alarm 0%, shutdown - 10%, switch -

20%, temp. switch 100°C




5 User InterfaceThis chapter describes the user interface and the basics of the X-control. For further information see User Manual, X-range aircompressors, X-control.

5.1 Keypad

a. Start – push to start thecompressor, or to set in a startedcondition.

b. Stop – push to stop thecompressor.

c. Escape / cancel – push to step

back one menu navigation level.d. Minus / down – Push to scroll

down through menu, menu itemoptions or decrement value.

e. Plus / up – Push to scroll up throughmenu, menu item options orincrement value.

f. Enter – push to confirm selection orvalue adjustment.

g. Menu – push to enter the menus.

h. Reset – push to reset and clear faultcondition.

Note

Access codes are needed to enter thedifferent levels of menu level

User level: Use access code 0000

Service level: Use access code 0100

Start [a] and Stop [b] have one defined function and are not used for any other purpose.

Reset [h] will initiate a display jump to the fault code item if a fault condition remains active, or initiate a display jump to the statusitem if no active faults exist in normal display mode.

If reset [h] is pressed and held for longer than two seconds in menu mode, the system will exit menu mode to the normal operationaldisplay mode, page 00.

Enter [f] will lock a selected displayed menu item. This prevents the menu item from returning to the default value, after a short

delay. When locked, the „lock‟ symbol will show. To unlock, press Escape [c].

Escape / cancel [c] will initiate a display jump to the information item in normal display mode, page 00.

Plus[e], Minus [d], Enter [g] and Escape [c] are used to navigate menu mode and adjust menu parameters.Press the menu button [g], to enter menu mode.




5.2 LED indicatorsThe LED indicators on the front of the X-control are illustrated and described below:

a. Green LED indicator – continuouslylight indicates on; the compressor isrunning.

b. Yellow LED indicator – flashing lightindicates service warning, needsattention soon.

c. Red LED indicator – flashing lightindicates fault or alarm, needsimmediate attention.

When the controller is activated the LED indicators can appear as:

Continuous light – ON

Fast flash (on / off four times per second)

Slow flash (on / off once per second)

Intermittent flash (on / off every four seconds)

Information regarding the LED indicator flash will be displayed on the controller.

Machine state number in display Machine state or condition Status Fault Service

1 Controller initialization ON ON ON

2 Start inhibit condition Slow flash Slow flash OFF

3 No start inhibit condition OFF OFF** OFF

4 Semi standby OFF OFF** OFF

5, 9, 14, 17 Drain unload time start Fast flash OFF** OFF

6, 7, 10, 11, 18, 19 Running ON OFF** OFF

8, 12, 16, 22 Drain unload time stop Fast flash OFF** OFF

13 Fully standby Slow flash* OFF** OFF

20 Stop while pressure is loaded for leak test Slow flash* OFF** OFF

21 Stop and drain Slow flash* OFF** OFF

10 Alarm error ON Slow flash OFF

23 Shut down error OFF Fast flash OFF

Service warning OFF OFF** Slow flash

Service alarm OFF OFF** Fast flash

No start inhibit condition and auto restartfunction active

Slow flash* OFF** OFF

*SF = standby state, indicates that the compressor may start running at any time.

**SF = alarm condition




5.3 Display

The normal operational display, which is continuously displayed, if no fault code occurs, is described and illustrated below.

Note

The displayed values are updated onceeach 500ms, but faster update-ratesare used internally (for example whentriggering alarms).

a. Delivery pressure value.

b. Symbol showing receiver.

c. Activated functions are represented

symbolically.

d. Value items.

e. Units.

f. Symbols for pressure andcompressor status.

g. Information text.

P00 User menu

This is the user menu page, which is available to all users. Items are “view only” and cannot be adjusted. The menu contains all itemsthat an operator may need to view during routine operation, such as pressure or temperature values.

All available items can easily be selected using the up / + or down / - buttons on the front of the controller at any time. Informationregarding system settings and values will be displayed on the information text line [g].

Values, parameters and option settings are grouped into menu page lists. Items areassigned to a list according to type and classification.

Page lists are identified by page number, the normal operational display / user view menu

is page 00 as illustrated. All adjustable parameters and options are assigned to menu P01 or higher: an accesscode is required to access pages higher than user view menu in P00.

The pages on user level which require an access code are:

P01: User settings

P02: Fault log

P03: Service log

P80: ISC operational

The default access code for these pages is = 0000.

The display will provide clear and early warning for temperature, high pressure stage, low pressure stage and oil level, making itpossible to respond to any potential problems while the situation is easy and inexpensive to correct.

When a fault condition occurs the fault code becomes the first page 00 list item, and the display will automatically jump to display thefault code. Several fault codes can be viewed at the same time by pressing the up / + or down / - buttons. The user menu item willdisappear when the fault condition is resolved and reset.




Display invert

The display back light level has been set to enable a “continuous use” display service life, providing good readability in al l ambient lightconditions. LCD display service life is defined as the time period before the backlight reduces to 50 % of initial brightness.

Increasing the back light level setting above the default will reduce the display service life.

When a keypad button is pressed the display backlight will automatically increase 2 levels in brightness.

The backlight will remain at this brightness level for a period of 10 minutes after keypad activity ceases.

The standard display and the inverted display are illustrated below. Please refer to configuration menu P09 in the “X-control Usermanual” for more details regarding the display back light settings procedure.

0 = standard 1 = inverted




5.4 SymbolsSymbols that can be displayed on the controller are illustrated and explained in the tables below.

Control pressure status symbols

Pressure is below the Unloadpressure set point value.

Pressure is above theload pressure set pointvalue.

Note

Status symbols are continuouslydisplayed.

Pressure is between theunloaded and load pressure setpoint values

Compressor status symbols

Stopped, not in an active stat. Running, not loaded. Note

Status symbols are continuously

displayed.Standby, not running but in anactive stat.

Loaded.

Menu mode navigation symbols

User level Note

These symbols show the menu accesslevel.Service level

Menu mode navigation symbols

User settings Fault log Note

These symbols show the general menutype.Service log Shutdown settings

Alarm settings Inhibit settings

Diagnostics Sensor calibration

User, “view only” Internal system control

Configuration settings Service reset

Function symbols

Indicates that all items in themenu page are locked andcannot be adjusted.

Time

Unlocked symbol; item iseditable.

Oil level




Function symbols

Locked symbol; displayadjustment is inhibited. Motor current

Real time clock Alarm, warning

Pressure Drain output is energized

Temperature Service

Start counter Full automatic mode

RS485 network pressureregulation control,

(flashing = data link fault)

Test safety valve mode

Power failure automatic

restartTest drain valve mode

Remote Pressure Control Semi automatic mode

Remote start/stop control Short circuit

Emergency stop activated Start inhibit

Heater “on” Time delay

Running Drain interval

Air receiverMotor current start updelay

Item “ID” Menu

Running hours Service hours

Language setting symbolEnglish Italian

German Dutch

French Turkish

Spanish




5.5 Menu structureThe display menu is divided in to several levels; the table below gives you an overview and a description of the menu levels andstructure.

Level Menu page Description

Access code, user level Access code required:The default code = 0000

01 Logged error #1v

30 Logged error #30

The fault log menu contains the last30 fault codes in chronological order.P02: Fault log

En Enable ISCPU ISC unload pressurePL ISC load pressureSC Sequence interval

P80: ISC operational

01 Logged service item #1v

65 Logged service item #65

The service log menu contains acomplete service overview.The items are view only.

P03: Service log

M> Mode (Semi or Full)MH Motor heating functionPU Unload pressurePL Load pressureD1 Drain unload time start

D2 Drain unload time stopDI Drain interval timeDO Drain time openP> Pressure unitsT> Temperature unitsL> Language selectionSS Start sourceLS Load sourceCt Compressor typeSN Serial number (controller)

The user setting menu contains adjustableparameters and options. Furtherinformation regarding these settings isdescribed on next page.

P01: User settings

Pressure units: Temperature units:BarPSIkPaMPakg/cm2

°C°F

C> Compressor status / RTCI> Information screenN> Compressor nameP1 Delivery pressureP2 Compressor HP pressureP3 Compressor LP pressureT1 Delivery temperature A6 Analogue input 6L1 Compressor oil level ** A7 Compressor motor currentHR Total running hoursST Start counterHS Hours until service due

IS ISC sequenceSC ISC seq. change int. counter

The user menu shows normal operationalvalues and information. This is the defaultdisplay menu, no access code is required.Items are view only and cannot beadjusted.

P00: User view

** Sensor for oil level L1 has 2

channels: 1 Digital + 1 Analog, onlyshown when oil level is enabled




P01 User settings:

Menu page DescriptionMode Semi or Full Mode settings for Semi or Full operation

mode.

Motor heating function Motor heating function. Always off when

motor is running.

Unload pressure Setting of the unload pressure (stop).

Load pressure Setting of the load pressure (start).

Drain unload time start Time period setting for the unloaded start.

Drain unload time stop Time period setting for the unloaded stop.

Drain comp. Interval time Time period setting for the drain intervaltime during load operation.

Drain open time Time period setting for the drain openingtime during load operation.

Pressure units Types of pressure units to be chosen.

Temp units Types of temperature units to be chosen.

Language selection Selection of language. English is thedefault.

Start source Setting of different start sources. Thedefault is the keypad start / stop key onX-control. Options are network or remotedigital input.

Load source Setting of different load sources. Thedefault is start / stop pressure transmitteron receiver or pressure line. Options arenetwork or remote digital input.

Note

If ISC operation in menu P80 isenabled, the network option is lockedand cannot be changed before ISC is

disabled.

Compressor type View of compressor type

Serial number View of controller serial number




Menu navigation

Access to menu mode pages is dependent on authority level determined by the accesscode used. To enter menu mode:

1. Press the menu button .

An access code will be displayed and thefirst code numeric character will flash.

1. Use the + / - buttons to select anumber.

2. Confirm the number by pressing the

enter button .

Repeat procedure until all numeric code characters are selected.

When the code is selected you will get access to the menu mode pages. An invalid codewill return the display to normal operational mode; page 00.

Each menu mode page is identified symbolically and by language text.

The first left symbol defines the menu page access level. The second right symboldefines the general menu type.

3. Press the + / - buttons to scroll throughthe menu pages.

4. Press the enter button to enter thedesired menu page

Each menu page contains a number of items. The first item on the list will be highlighted,as illustrated below.

5. Press the + / - buttons to scroll throughthe items on the list. The list will wraparound.

6. Press the enter button to confirmthe selection or value. To abandon anadjustment at any time press the

escape button , the original value oroption will be maintained in memory,and the screen will return to page itemlist.

7. Press the escape button to return tothe menu page selection screen.

Note

When the first list item is highlighted thelast list item can be seen at the top ofthe list; this immediately indicates thenumber of listed items.

A menu page may contain items that are“view only”. A key symbol will be displayedto indicate that all items on the menu pageare locked and cannot be adjusted, asillustrated.

To immediately exit menu mode and returnto the normal operational display, press

and hold the reset button for severalseconds at any time.

Note

Menu items can be locked for “viewonly” when the compressor is running.The compressor must then be stoppedbefore adjustments can be performed.

Any value or option adjustment that has not been confirmed and entered into memory willbe abandoned and the original setting will be maintained.




Fault, warning and alarm

The controller will indicate if a fault, warning or alarm condition occurs in the system. The different fault state conditions will bedisplayed with specific codes. The active fault code becomes an additional item on the display until the fault condition is resolved andreset. Each fault type is identified symbolically and each fault code is unique.

Each code character gives you specific information regarding the fault condition, as described below:

a. The first letter and number of thecode indicates the fault type.

b. The second number indicates theinput location number.

c. The third number indicates the inputnumber.

d. The last number indicates the faultdescription number.

A fault condition is a detected abnormality that must be indicated to operator personnel. It may require controller automated safetyaction, depending on fault type and definition. The fault, warning and alarm conditions that can be displayed are:

Start inhabit fault (Code S): A start inhibit fault is a condition that may present a danger or cause damage to the compressor if started whilst the condition ispresent. Start inhibit faults are only triggered if a compressor start from the “ready to start” condition is attempted. Star t inhibit faults arenot triggered during an automated motor start sequence from the standby condition. Start inhibit faults are self-resetting. A start inhibitfault code (S) is displayed when triggered but is not recorded in the fault log.

Alarm fault (Code A): An alarm fault is a warning condition that does not present an immediate danger or potential damage to the compressor. Alarm stateswill not shutdown the compressor or affect normal operation. An alarm fault code (A) is displayed and must be manually reset to clearonce the condition has been resolved or no longer exists.

Shutdown fault (Code E): A shutdown fault is a condition that may present danger or potential damage to the compressor if the condition persists. A shutdownfault will cause the controller to stop the compressor. A shutdown fault code (E) is displayed that must be manually reset to clear oncethe condition has been resolved or no longer exists.

Service warning (Code SW) / Service alarm (Code SA): A service warning or alarm fault is a warning condition that does not present an immediate danger or potential damage to thecompressor. A service warning or alarm state will not shutdown the compressor or affect normal operation. A service warning faultcode (SW) is displayed and must be manually reset.

If a service alarm fault code (SA) is displayed it must be manually reset by entering an ID-number, or simply by entering to clear oncethe service condition has been resolved or no longer exists. However, if a service alarm is triggered before its related service warninghas been reset, the warning will be reset by the alarm. See P04 Service alarm reset menu for further details.




6 Installation and Operation

6.1 Installation

All deliveries of compressor installations are accompanied by documentation of theinstallation‟s dimensions and mounting points. The documentation will also includeinstallation instructions, illustrating the recommended assembly of equipment and pipeconnections.

To achieve problem-free operation, it is important that the base-plate is sufficiently rigidand free from vibrations caused by other machinery. The base of the compressor must lieflat on the base-plate.

The normal ambient air temperature is 20-45°C and must not exceed 55°C. Warm intakeair increases the risk of coking. Transmitters and solenoid valves must not be exposed totemperatures above 80 °C.

The cooling water pipes must be installed correctly to avoid air pockets.

The compressed air outlet temperature should be approximately 15-30°C above coolingwater inlet temperature. Adjust cooling water flow (l/min) to achieve this temperaturedifference.

The compressor installation must not be closely surrounded by other equipment, whichcould inhibit maintenance performances. The recommended maintenance space on allsides is 600 mm.

This manual includes instructions for handling of the compressor after installation. It isimportant that the instructions are followed carefully to avoid problems duringcommissioning and further use of the compressor.

Note

Please refer to the General Arrangement and Installation drawingsfor specific details.

ISC installation

ISC:

Warning

Wire polarity is important.

Use 2-wire, 0.3-0.5mm2, twisted pair earth shielded data cable with a total system network length no greater than 1.0km (3280ft).

Data cable terminal connections vary.

Consult the manuals and drawings for details before installing the ISC communication between the compressors.

RS485 data communications and other low voltage signals may be subject to electrical interference. This potential can result inintermittent malfunction or anomaly that is difficult to diagnose. To avoid this possibility always:

Use earth shielded cables, securely bonded to a known good earth at one end. In addition, give careful consideration to cable routingduring installation.

Never route an RS485 data communications or low voltage signal cable alongside a high voltage or 3-phase power supply cable. If itis necessary to cross the path of a power supply cable(s), always cross at a right angle.

If it is necessary to follow the route of power supply cables for a short distance (for example: from a compressor to a wall along asuspended cable tray) attach the RS485 or signal cable on the outside of an earthed cable tray so that the cable tray forms anearthed electrical interference shield.

Where possible, never route an RS485 or signal cable near to equipment or devicesthat may be a source of electrical interference (for example: 3-phase power supplytransformer, high voltage switchgear unit, frequency inverter drive module, radiocommunications antenna).




Pressure transmitter location:

The system pressure transmitter (PT11) must be located in a position that will continuously experience pressure that is common to thedelivery of all compressors in the system.

Pressure side pressure control:

6.2 Before and after operation

Before operation

The Sperre compressor sensors and starter are real-time tested in our test facilitiesbefore delivery from the factory.

Before initial start-up, and after long periods out of use, the following operations need tobe carried out in the sequence given:

1. Check the oil level (sight glass).

2. If the compressor has been out of service for more than 6 months, lubricate thevalves, cylinder walls and crank bearings.

3. Turn the compressor shaft a few revolutions, by turning the fan.

4. Open valves on the air discharge line between the compressor and the receiver.

5. Ensure that power is available and that the electrical plug-in cables are fittedproperly.

6. Turn the power switch to the “on” position.

When power is switched on, all displayelements and LED indicators will beswitched on for three seconds. Thedisplay will then show the software versioncode for a further 3 seconds beforestarting-up is completed and the normaloperating display will show.

The display will be switched on, and“ready to start” will be displayed if noalarms or shutdowns are active.

Note

If the X-control is not centralized withthe ships central alarm system, thecontroller needs daily inspection toobserve fault, warning or alarmconditions.

7. Start the compressor, by pressing the green start button (if not in standby mode). Thecompressor is now in active condition ready to respond to changes in deliverypressure.

The Sperre compressors are designed to maintain safe operation with a minimum ofmaintenance.

The operation procedures for the different modes are described on the following pages.




Preservation

If the compressor is to remain unused for a long period, lubricate the valves and cylinder walls with oil. The compressor must bestarted from time to time: please refer to procedure “before operation”.

The following precautions must be taken when storing the compressor:

1. Store in a dry place with the lowest possible relative humidity.

2. Shut off the cooling water circulation.

3. Coat relevant surfaces, especially unpainted surfaces, with rust inhibiting oil or similar.

4. Turn the compressor shaft a few revolutions, by turning the fan, once a month.

5. For storing longer than six months, lubricate all valves and cylinder walls with corrosion inhibiting oil. Clean and check beforestarting up.

6.3 General operationThis chapter provides important information regarding normal, ISC and emergencyoperation of the compressor.

Before operating the equipment, please refer to Chapter 2 for the personal safetyinstructions.

Warning

If any malfunction, warning or alarm isdetected during operation, themalfunction must be given immediateattention.

The compressor can be set to two different normal operating modes:

Semi-automatic mode S>

Full-automatic mode F>

In the semi-automatic mode of operation, the operator is in command of when the compressor runs.

In full-automatic mode, the delivery pressure controls the start and stop of the compressor once the operator has started the

compressor.

The operator can also choose to start the compressor in two different test modes:

Test mode TS

Test mode TD

When exiting the test mode, the compressor will automatically return to the normal set mode S> or F>.

The compressor can also be remotely started and stopped.

Semi-automatic mode S>

Semi automatic is a mode of operation in which the operator controls compressor start and the delivery pressure controls stopoperation. After the compressor has stopped the operator have to manually start the compressor again.

Start:

1. Press the start button to start the compressor

The compressor will achieve the set unload pressure and then stop.

When the operator presses the start button again, and the pressure is above the load level, the controller will hold and wait for thepressure to fall before automatically starting the compressor; if the pressure is below the load level the compressor is startedimmediately and the pressure will rise.

When the unload pressure level is achieved the compressor will stop. The compressor will only start again if the operator presses thestart button.

The green LED indicator will appear as a slow flash to indicate semi standby, and that the compressor can be started again at anytime. The compressor will only start again if the operator presses the start button.

Stop:

1. Press the stop button. The operator can stop the compressor at any time.




Full automatic mode F>

Fully automatic is a mode of operation in which the delivery pressure controls compressor start and stop operation once the operatorhas started the compressor.

Start:

1. Press the start button to start the compressor

If the pressure is below the load level the compressor is started and the pressure willbegin to rise. When the unload pressure level is achieved, the compressor will stop andthe compressor will remain active in a standby condition.

The compressor will automatically start again when the delivery pressure falls below theload pressure level. This cycle will continue until the compressor is stopped by pressingthe stop button.

When the delivery pressure is below the unload level, but above the load level, thecompressor can be started again immediately by pressing the start button. This willcause the compressor to start and increase pressure to the unload level, without theneed to wait for pressure to decrease to the load level.

The green LED indicator will appear as a slow flash to indicate fully standby, and that the

compressor may start running at any time.

Stop:

1. Press the stop button, to exit fully automatic operation, and stop the compressor.

Warning

In automatic mode, the compressorwill automatically start.




Remote modes

For remote operation the remote digital input start source and load source must bemanually set to remote digital input on the controller, as described in the followingprocedure:

Start source (SS) setting: 0 = keypad, 1 = network, 2 = remote digital input.

This is the remote function replacing the start / stop buttons on the local control panel, foroptional start operating. The signal, if closed, set the compressor in started condition andwill start the compressor if it is ready to start. The signal, if open, will set the compressorin stopped condition. The remote start / stop function must be set in X-control usersetting menu P01 – item SS = 2 (remote digital input). Default is SS = 0 (local start / stopbutton).

Load source (LS) setting: 0 = pressure transmitter, 1 = network, 2 = remote digitalinput.

This is the remote function replacing the local receiver pressure transmitter, for optionalremote pressure control. If the pressure transmitter on the receiver is not being used forthis purpose (local control), a digital remote signal from vessel automation system can beused for this purpose. Closed signal contact for start / loading condition and open signalcontact for stop / unloading condition / stand by. The remote function must be set in X-control user setting menu P01 – item LS = 2 (remote digital input). Default is LS = 0

(receiver pressure transmitter).

Setting start source:

1. Press the menu button .

2. Select the access code 0000, confirm each number by pressing the enter button .

3. Use the + / - buttons to select page P01 / user setting menu.

4. Press the enter button to enter the menu P01.

5. Use the + / - buttons to select the start source (SS) and press the enter button , toconfirm the selection.

6. Use the + / - buttons to select the number 2. Press the enter button to confirm theselection.

Setting load source:

1. Use the same procedure to set to the Load source LS.

2. The controller is now set to remote operation only, but the stop function will alwaysbe available locally.

Note

Please note that a push button withreturn cannot be used for remoteoperating. Only a switch or a push

button with locked positions can beused.

Remote start:

When the remote start/stop function is enabled in X-control user setting menu P01, thecompressor will execute a normal start sequence when the remote start/stop inputchanges state from open to closed circuit. If closed, the remote start/stop input must beopened and closed again to initiate a new remote start sequence. Local controller start

function is inhibited.

When the delivery pressure is below the unload level, but above the load level, thecompressor can be started again immediately by switching the remote signal contact ofan on again within one second. This will cause the compressor to start and increasepressure to the unload level, without the need to wait for pressure to decrease to theload level.

Remote stop:

When the remote start/stop function is enabled in the X-control operation menu P01, thecompressor will execute a controlled stop, as if the control panel stop button had beenpressed, when the remote start/stop input is open circuit. Local control panel stop will stillbe available.




Remote unload:

When the remote load source function is enabled in the X-control operation menu P01an open circuit remote digital signal will automatically stop the compressor and go to astand-by mode.

Remote load:

When the remote load source function is enabled in the X-control operation menu P01 aclosed circuit remote digital signal will automatically start the compressor again if

operation mode is "Full automatic". In "Semi automatic" the green start key has to bepressed for a restart.

Local / remote operation philosophy for start and stop commands

Start and stop commands:

O = possible

X = not possible

Mode: Local mode: Remote mode:

SEMI AUTO and FULL AUTO

Local Side Remote Side Local Side Remote Side

Start Stop Start Stop Start Stop Start Stop

O O X X X O O O




6.4 Internal system control (ISC)The controller is equipped with a function that will enable pressure control regulation and sequence management. This feature can beused to create an air compressor system, of up to 8 compressors, operating coherently to a single pressure target with automatedtimed sequence rotation.

The ISC‟s control strategy consists of two sub-strategies:

1. The compressor „Rotation‟ strategy

2. The compressor load „Control‟ strategy

The rotation strategy defines how the compressors are re-arranged, or re-ordered, into a new sequence at each routine „Rotation‟event. Rotation events are triggered by a cyclic interval timer.

The compressor load „Control‟ strategy defines how the compressors are utilized in response to variations in system pressure.

Each compressor in a system is initially assigned to the ISC with a fixed and unchanging number reference, 1 to 8. The „duty‟ that acompressor is assigned in any set „Rotation‟ sequence arrangement is defined by a letter, A to H:

A = the „Duty‟ compressor, the first to be utilized.

B = the „Standby‟ compressor, the second to be utilized.

C = the „Second Standby‟ compressor, the third to be utilized.

D = the „Third Standby‟ compressor, the forth to be utilized, and so on.

The primary function of rotation is to efficiently operate a compressed air system consisting of fixed capacity output compressors. Theroutine rotation assignments can be modified using „Priority‟ settings to accommodate for a differentially sized, preferred or non-preferred compressor(s).

Rotation:

Each time the set rotation interval elapses a sequence rotation occurs and the sequenceassignment for each compressor is re-arranged.

The compressor that was assigned for duty (A) is re-assigned as last standby (D) and allother compressor assignments are incremented by one

Control:

The compressors are utilized, in response to changing demand, using a „FILO‟ (First In, Last Out) strategy. The „duty‟ compressor (A) isutilized first followed by (B) if demand is greater than the output capacity of (A). As demand increases (C) is utilized followed by (D) ifdemand increases further.

As demand is reduced (D) is the first compressor to be unloaded, followed by (C) and then (B) if demand continues to fall.

The last compressor to be unloaded, if demand reduces significantly, is (A). The compressor assigned as (A) in the sequence is thefirst to be loaded and the last to be unloaded

#1

1 2 3 4

#2

#3

#4

A B C D

D A B C

C D A B

B C D A




Activating ISC, (menuP80 and P01)

Please follow the procedures below to accomplish correct activating of the ISC:

The master controller must be set to enabled = network item “En” in X-control menu P80as described below: Note

The X-controller with the lowest serialnumber is recommended for use asthe master controller.

1. Select one of the X-controls to besystem master controller.

2. Press the menu button .Selectaccess code “0000”, confirm eachnumber by pressing the enter button

.

Note

When ISC operation is enabled, theload source will automatically be set to(1) network. To enable deliverypressure sensor (0) or remote (2) loadsource; disable the ISC operation andset the wanted function in menu P01.

3. Use the + / - buttons to select P80 ISCoperational.

4. Press the enter button to confirmand enter the menu page P80.

5. Use the + / - buttons to select the “En”line as illustrated, and press the enter

button to select.

6. Use the + / - buttons to select item 1

enabled, press the enter button toconfirm the ISC setting.

0 = disable.

1 = enable.

7. The ISC setting is now activated, asillustrated.

The other adjustable settings on this page (P80) can easily be adjusted:

SC: Sequence interval is set to default 24 hours. Range 1 – 750 hours. Sets thesequence „Rotation‟ interval or time. The compressor sequence assignments will berotated each time the sequence change interval time expires.

Pu: Unload pressure is set to default 29,0 bar.

PL: Load pressure is set to default 26,0 bar.

Once ISC is activated ISC can be started and stopped independently of the master aircompressor. Navigate to the ISC sequence display item in the user view of the mastercontroller.




All slave controllers must be set to Load source = network at item “LS” in X-control menuP01, as described below:

1. Select one of the slave controllers

Press the menu button .

2. Select the access code 0000, confirmeach digit by pressing the enter button

.

3. Use the + / - buttons to select pageP01 / user setting menu.

4. Press the enter button to enter usersetting menu page.

5. Use the + / - buttons to select the “LS”item, load source. Press the enter

button to select.

6. Use the + / - buttons to select the

default “1”. Press the enter buttonto confirm the selection.

7. The first slave controller is now set.Repeat the procedure for the nextslave controllers until all are set.

Note

Please see X-control user manual forfurther details regarding using the ISCfunction.




6.5 Emergency operationThe system can be overridden using an emergency run switch on the inside of the X-starter. If normal control of the compressor fails, and power is available, the emergencyswitch will force the compressor to run.

For emergency operation of the compressor please follow the procedure below:

Warning

The compressor must not be leftunattended while running in

emergency mode!1. Manually check the oil level, and

visually observe that there are noabnormalities with the compressor.

2. Manually open the drain valve [b] onthe compressor by using ascrewdriver.

3. Turn the emergency switch [a] on theinside of the X-starter to theemergency position. The compressorwill now start.

4. Manually close the drain valve [b] on

the compressor by using ascrewdriver.

5. Observe and manually check that thecompressed air temperature is notabove normal.

6. The pressure increase should bemonitored during all running period.

7. Before the compressor is stopped,carefully open the drain valve [b].

8. Stop the compressor by turning theemergency switch [a] to the “normal”position.

Warning

Never carry out the emergencyoperation alone. Monitor the air-receiver pressure and shut down thecompressor immediately whenpressure level is reached.

No surveillance or alarms will function,except for local emergency stop and

motor overload control, which will be inan active state.




7 Troubleshooting

7.1 Abbreviations

Abbreviation Description CommentsCT1

DV1

DV2

F1

F11

F12

PT11

PT12

PT13

PT14

LT15

LS15

PTC

RTC

S0

TT14

XPC

Current transmitter

Drain valve HP

Drain valve LP

Thermal overload relay

MCB - Motor circuit breaker

MCB - Motor circuit breaker

Receiver pressure transmitter

Compressor HP Pressure transmitter

Compressor LP Pressure transmitter

Compressor oil pressure transmitter

Compressor oil level transmitter

Compressor oil level switch

Electric motor thermistor control

Real time clock

Local emergency stop button

Temperature transmitter HP outlet

Expansion card

Only for water-cooled XW200-500

Only for water-cooled with cw pump

Only for pressure lub. compressors

Only for pressure lub. compressors

LT15 and LS15 are located in same unit

7.2 Service warning (SW) and alarm (SA)

When a service warning or alarm appears on the display (SW / SA)

Service warning (pre-alarm):

When a service warning occurs the controller will display the “Service Warning” indicating the service type, code and contact details forservice arrangements.

A service warning will occur 200 running hours or 3 months prior to a service. The yellow service LED- indicator will appear as slow-flash. The Service Warning indication will alternate with the normal running display.

1. Reset the service warning by pressing the reset button on the controller. Theservice warnings will not occur again. This facility is intended to provide pre-warningenabling service arrangements.

2. Order the Sperre service kit. Please refer to “Service procedures overview” in theService manual, for the service kit ordering number.

A Sperre service kit (A, B, C, D or E) contains all necessary spare parts with the relevantstep by step service procedures.

Note

The text line on the display will indicatethe type of service.

Service A will only appear once,throughout the life time of thecompressor, and will only be indicatedwith a service alarm.




Service alarm (service due now):

When the service interval time expires the controller will display the “service alarm” Theyellow service LED-indicator will appear as fast-flash.

3. The service type displayed must be performed with the relevant Sperre service kit.

4. The Service alarm indication can be reset before the service is complete and the“service interval reset procedure” has been carried out. In this case, the “Serviceindicator” (yellow LED) will change to be illuminated continuously. 24 hours after the

alarm has been reset, the indicator will start flashing again and the screen will toggleagain. This goes on until the proper reset procedure has been carried out.

Please refer to the “X-control Manual” for the “Service alarm reset procedure”.

Note

Service warnings / alarms will notinterfere with compressor running. Forsafe running, all services should beexecuted according to serviceschedule.

Service warnings

Service warning code Text displayed Failure Corrective action

SW4824 “SERVICE B” Pre-alarm, service B due soon Press the “reset” button. Order service kit.Please refer to “Service procedure overview” in

the Service manual

SW4834 “SERVICE C” Pre-alarm, service C due soon Press the “reset” button. Order service kit.Please refer to “Service procedure overview” inthe Service manual

SW4844 “SERVICE D” Pre-alarm, service D due soon Press the “reset” button. Order service kit.Please refer to “Service procedure overview” inthe Service manual

SW4854 “SERVICE E” Pre-alarm, service E due soon Press the “reset” button. Order service kit.Please refer to “Service procedure overview” inthe Service manual

Service alarm

Service alarm code Text displayed Failure Corrective action

SA5814 “SERVICE A” Service hours countdown timeexpired

Service A must be performed, refer to “Serviceprocedure overview” in the Service manual

SA5824 “SERVICE B” Service hours countdown timeexpired

Service B must be performed, refer to “Serviceprocedure overview” in the Service manual

SA5834 “SERVICE C” Service hours countdown timeexpired

Service C must be performed, refer to “Serviceprocedure overview” in the Service manual

SA5844 “SERVICE D” Service hours countdown time

expired

Service D must be performed, refer to

“Service procedure overview” in the Servicemanual

SA5854 “SERVICE E” Service hours countdown timeexpired

Service E must be performed, refer to “Serviceprocedure overview” in the Service manual




7.3 Alarms (A)

When an analogue input alarm occurs on the display

When an analogue input alarm occurs the controller will display one of the fault codes listed below.

The fault code must be manually reset on the controller to clear once the condition has been resolved or no longer exist. Alarm stateswill not shutdown the compressor or affect normal operation.

Analogue input alarm errors

Alarm code Text displayed Failure Possible cause Remedy

A_2112 “DEL PRESS LOW” Delivery pressurelow (PT11)

X-control unit setting Check alarm parameter settings in alarm menu (seeX-control manual).

Transmitter out ofrange

Check values in diagnostic menu (see X-controlmanual). Fine calibrate in calibration menu (see X-control manual). Replace transmitter if defective.

Air leakage Check piping between compressors and air receiver.

Check if drain valve(s) are open or closed.

Check air receivers.

Check compressors.

Compressorvalve(s) or drainvalve(s) failure

Check and replace if defective.

Safety valve(s)failure


A_2118 “DEL PRESS HIGH” Delivery pressurehigh (PT11)



Emergency runmode

Switch to normal mode

A_2148 “DEL TEMP HIGH” Deliverytemperature high(TT14)

X-control unit setting Check alarm parameter settings in alarm menu (seeX-control manual).



Air coolers pressure

drop

Check all air coolers (LP, Pre-cooler HP and HP).

Replace if defective.

Cooling watertemperature andflow.

Check cooling water temperature and ensure thatcooling water flows.

Enclosure and fan Check that enclosure and fan is correctly mountedand ensure that no air inlet or outlet is blocked.

Compressor runningdirection

Check and reconnect cables in el-motor connectionbox if wrong direction.

Valve failure Check valve HP and LP for leakage / failure. Replaceif defective.

Air cooler failure Water-cooled compressor. Check cooler for internalleakage. Replace cooler if defective.

A_2126 “LEAKAGE HIGH” HP pressure leaktest failure

Air leakage Check piping, hoses, valves (valve HP / LP and drainvalves) and coolers.




Alarm code Text displayed Failure Possible cause Remedy A_2128 “HP PRESS HIGH” Compressor HP

pressure high (PT12)X-control unitsetting

Check alarm parameter settings in alarm menu (seeX-control manual).



Air blockage Check piping and outlet valve

Non return valvefailure

Check non return valve and replace if defective.

Emergency runmode

Switch of emergency run mode if used and use full orsemi-automatic mode.

A_2138 “LP PRESS HIGH” Compressor LPpressure high (PT13)

X-control unitsetting




Non return drainvalve failure

Check non return drain valve and replace if defective.

Valve HP failure Check gaskets and valve for internal leakage andreplace if defective.

Emergency runmode

Switch of emergency run mode if used and use full orsemi-automatic mode.

A_2145 “DEL TEMPSENSOR”

Delivery temperaturesensor fault (TT14)

Transmitter failure Check temperature transmitter and replace ifdefective.

Cables connectionfailure

Fix or change cables / connections

A_2152

(Optional)

“OIL LEVEL LOW”

“OIL PRESSURELOW”

Compressor oil levellow (LT15)

Compressor oilpressure low (PT16)

X-control unitsetting


Transmitter out of

range

Check values in diagnostic menu (see X-control

manual). Fine calibrate in calibration menu (see X-control manual). Replace transmitter if defective.

Oil level too low Fill to correct oil level (check sight glass and X-control display).

Oil pressure too low Check oil level / oil filter / oil pump

A_2155 “OIL LEVELSENSOR”

Compressor oil leveltransmitter LT15 fault




A_2165 "ANA6_SENSOR" Analogue input 6 fault




A_2175 “CURRENTSENSOR”

Compressor motorcurrent sensor (CT1)




Motor current startup delay too short

Increase time setting in config. menu 09, item 03 -CT

A_2816 “POWER FAILURE” Power failure Voltage out of range Check main voltage, adjust voltage to right level.Check transformer voltage and input voltage on theX-control power supply and replace transformer ifdefect.

Power failure whenauto restart is setto”0”

Compressor will not restart automatically when set to“0”. Press the start button and the compressor willautomatically restart and the fault code will onlyappear in the error log.




A_2836 “RTC FAILURE” RTC failure Real time clockfailure.

Contact Sperre.

7.4 Start inhibits (S)

When a Start inhibit error code appears on the display

If temperature (T1) is below the set limit when a start is attempted the motor will not start and a start inhibit error code will be displayed.The temperature must increase above the set limit before a start is allowed.

Non-Adjustable Start Inhibit Items:

HP Pressure:

P2 if compressor HP pressure level is over the set limit when a start is attempted the motor will not start and a start inhibit error codewill be displayed. The HP pressure level must decrease to below the set limit before a start is allowed.

The P2 pressure limit is determined by the compressor type selection.

LP Pressure:

P3: If compressor LP pressure level is over the set limit when a start is attempted the motor will not start and a start inhibit error codewill be displayed. The LP pressure level must decrease under the set limit before a start is allowed.

The P3 pressure limit is determined by the compressor type selection.

The start inhibit error codes are self-resetting.

Start inhibit error codes

Start inhibitcode

Text displayed Failure Possible causes Remedy

S_3143 “DEL TEMP LOW” Delivery temperaturelow (TT14)

X-control unit setting Check alarm parameter settings in start inhibitmenu (see X-control manual).



Ambient temperaturetoo low

Check ambient temperature.

S_3127 “HP PRESS HIGH” Compressor HPpressure high (PT12)



Internal pressure toohigh

Check drain valve(s) and replace if defective.

Air blockage Check drain piping.

S_3137 “LP PRESS HIGH” Compressor LPpressure high (PT13)



Internal pressure toohigh

Check drain valve(s) and replace if defective. Onlyfor water cooled XW200-500.

Air blockage Check drain piping.




7.5 Immediate stop shutdown errors (E)

When an immediate stop shutdown error occurs on the display

When an immediate stop shutdown error occurs the controller will display one of the fault codes listed below. A shutdown fault will

cause the controller to stop the compressor.

The error code must be manually reset on the controller to clear once the condition has been resolved or no longer exist.

Digital input shutdown errors

Shutdowncode


E_0010 “LOCAL EM`CYSTOP”

Local emergencystop (S0)

Emergency stop engagedlocally

Check that neither personnel nor machinerycan be harmed before disengage.

Loose wires Check and tighten all loose connections.

E_0020 “EXT.EM`CY STOP” External or remoteemergency stop

Emergency stop engagedremotely

Check that neither personnel nor machinerycan be harmed before disengage.


E_0030 “MOTOROVERLOAD”

Compressor motorcurrent high (F1)

Thermal overload relayfailure.


Cable failure Check cable dimension and connections.

Contactor failure Check and replace if defective.

Electric motor failure Check and replace if defective.

Compressor failure Check if it is possible to turn compressormanually by hand. Check thoroughly allmechanical moving parts for wear.

E_0060 “DIG:INPUT 6”

Multi function input

1. CW pump overload2. CW flow low3. CW pressure low4. Optional equipment

Digital input 6 opencircuit


Cooling water pumpoverload or MCB (F10)switched off

Check pump and pump motor for failure andreplace defect. Switch MCB on if off.

Cooling water flow low Check cooling water flow and adjust flow tocorrect level.

Cooling water pressurelow

Check cooling water pressure and adjustpressure to correct level.

Dig. Input 6 failure Check optional equipment.E_0070

(Optional)

“OIL_ LEVEL /TEMP” Oil level low (LS15) Oil level too low Fill to 100% (check sight glass and X-controldisplay).


Oil temp high(LS15)

Oil temperature too high Check cooling system or ambient temperature


“OIL_PUMP” Overload oil pump Check oil pump

MCB Off MCB switched off Check MCB, switch on if switched off.

E_0080 “MOTOROVERHEAT”

Digital input 8 PTC Electric motor failure Check motor temperature and replace motor ifdefective.

Thermistor failure Measure the thermistors.

Connection failure Check if motor is correctly connected with theright cable dimensions. Always connectaccording to the motor rating plate information.




Analogue input shutdown errors

Shutdowncode


E_0115 “DEL PRESSSENSOR”

Delivery pressuretransmitter failure (PT11)

Transmitter failure Check delivery pressure transmitter andreplace if defective.

Cables connection failure Fix or change cables / connections

E_0119 “DEL PRESS HIGH” Delivery pressure high(PT11)

Transmitter out of range Check values in diagnostic menu (see X-control manual). Fine calibrate incalibration menu (see X-control manual).Replace transmitter if defective.

Outlet valve failure Outlet valve failure

Non return valve failure Check piping and valves

Wrong ISC dampingsetting

Check ISC damping setting.

E_0125 “HP PRESSSENSOR”

Compressor HP pressuresensor failure (PT12)



E_0129 “HP PRESS HIGH” Compressor HP pressurehigh (PT12)

X-control unit setting Check alarm parameter settings in alarmmenu (see X-control manual).


Air blockage Check piping outlet, outlet valve andsafety valve HP.

Non return valve failure Check non return valve and replace ifdefective.

E_0135 “LP PRESSSENSOR”

Compressor LP pressuresensor failure (PT13)



E_0139 “LP PRESS HIGH” Compressor LP pressurehigh (PT13)



Non return drain valvefailure Check non return drain valve and replaceif defective.

Valve HP failure Check gaskets and valve for internalleakage and replace if defective.




Shutdowncode


E_0149 “DEL TEMP HIGH” Delivery temperature high(TT14)


Transmitter out of range Check values in diagnostic menu (see X-control manual). Fine calibrate incalibration menu (see X-control manual).

Replace transmitter if defective. Air coolers pressure drop Check all Air coolers (LP, Pre cooler HP

and HP). Replace if defective.

Cooling watertemperature and flow.

Check cooling water temperature andensure that cooling water flows.

Enclosure and fan Check that enclosure and fan is correctlymounted and ensure that no air inlet oroutlet is blocked.

Compressor runningdirection

Check and reconnect cables in el-motorconnection box if wrong direction.

Valve failure Check valve HP and LP for leakage /failure. Replace if defective.

Air cooler failure Water cooled compressor. Check coolerfor internal leakage. Replace cooler ifdefective.

E_0151 “OIL LEVEL LOW” Compressor oil level low(LT15)



Oil level too low Fill to correct oil level (check sight glassand X-control display).

E_0505 “SHORTCIRCUIT” Short circuit on XPCanalogue input

Transmitter failure Check and replace transmitter(s) ifdefective.

Wiring failure Check wiring and replace defectivewire(s).

Input failure Check values in diagnostic menu (see X-control manual). Check analogue inputand replace X-control unit if defective.

E_0821 “SHORTCIRCUIT” Short circuit on analogueinputs

Transmitter failure Check and replace transmitter(s) ifdefective.

Wiring failure Check wiring and replace defectivewire(s).

Input failure Check values in diagnostic menu (see X-control manual). Check analogue inputand replace X-control unit if defective.

E_0836 “SYSTEM ERROR” PLL unlock trip Control unit failure Replace X-control unit if defective.

E_0837 “COMMUNICATION” XPC expansion cardcommunication error

Communication failure Check communication between mainmodule and expansion module inside theX-control. Replace X-control if defective.

E_0866 “POWER SUPLLYLOW”

Power supply low Power supply failure Check power supply voltage.




7.6 Errors when no alerts are displayed

Error symptom Possible cause Remedy

High oil consumption Oil type Only use Sperre approved oil - change if wrong.

Piston ring wear Check piston rings and change if defective.

Cylinder lining wear Check cylinder lining for wear and change if defect.

Oil leakage Check for oil leakage.

High oil level Check oil level, drain to below 120 %

Wrong Amp reading Wrong transmitter range Check calibration menu (see X-control manual).

Electric motor failure Measure electric motor and replace if defective.

Transmitter out of range Check values in diagnostic menu (see X-control manual). Finecalibrate in calibration menu (see X-control manual). Replacetransmitter if defective.

High vibration levels Weak deck structure Check deck structure – strengthen if defective.

Weak base plate Check base plate – strengthen if defective.

Faulty isolator Check vibration isolators – change if defective.

Connection flexible tubes Check tube lengths, bending and air pulsation

High noise level Loose enclosure Fasten enclosure screws.

Loose motor cables Check and fasten motor cables if loose connection.

Bearing failure Check all electric motor and compressor bearings and replace ifdefective.

Low HP pressure Air leakage Check if drain valve(s) are open or closed.

Check air receivers.

Check compressors.

Compressor valve(s) or drainvalve(s) failure

Check valve HP and LP for leakage / failure. Check drain valve.Check gaskets and replace if defective.

Safety valve(s) failure Check and replace if defective.

Low LP pressure Air leakage Check if drain valve(s) are open or closed.

Check air coolers.

Check compressors.

Compressor valve(s) or drainvalve(s) failure

Check valve LP for leakage / failure. Check drain valve. Checkgaskets and replace if defective.

Safety valve(s) failure Check and replace if defective.

Compressor running

direction

Check and reconnect cables in electric motor connection box if

wrong direction.

Compressor do not load Defect drain/unload valve Check if voltage is available X* sec after start

Check if drain open time is set to X* sec (default) in menu P01

(*X depends of compressor type)

If voltage is ok, check if coil is ok

Check if valve is clean, if clogged with dirt it will not close

Check if relay output 2 (R2) is closed.



NOTE:







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